Heat exchanger tube precursor and method of producing the same

ABSTRACT

A heat exchanger tube precursor that allows manufacturing a heat exchanger having high corrosion resistance after brazing treatment is provided. The heat exchanger tube precursor includes: an Al alloy tube; and a flux layer including a Si powder, a Zn-containing flux, a Zn-free flux, and a binder, the flux layer being formed on an outer surface of the Al alloy tube.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is continuation in part of application Ser. No. 12/690,685, filed Jan. 20, 2010, which is continuation in part of application Ser. No. 11/218,595, filed on Sep. 6, 2005, which is a continuation of application Ser. No. 10/823,563, filed on Apr. 14, 2004, which claims priority to Japanese Patent Application No. JP 2003-128170, filed on May 6, 2003, the entire contents of each of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a heat exchanger tube precursor and, more particularly, relates to a heat exchanger tube precursor, which allows manufacturing a heat exchanger having high corrosion resistance after brazing treatment. The present invention also relates to a method of producing the heat exchanger tube precursor.

As shown in FIG. 2, a heat exchanger generally comprises a pair of right and left pipe bodies called header pipes 5, a multitude of tubes 1 made of an aluminum alloy installed in parallel at intervals from each other between the header pipes 5, and fins 6 installed between the tubes 1, 1. The inner space of each of the tubes 1 and the inner space of the header pipes 5 communicate with each other, so as to circulate a medium through the inner space of the header pipes 5 and the inner space of each of the tubes 1, thereby achieving efficient heat exchange via the fins 6.

It is known to constitute the tubes 1 of the heat exchanger from heat exchanger tube precursors 11 made by coating the surface of an Al alloy extruded tube 3, that has flattened cross section and a plurality of holes 4 for passing the medium as shown in perspective view of FIG. 1, with a flux containing a brazing material powder so as to form a flux layer 2. It is also known to make the Al alloy extruded tube 3 from material (JIS1050) that has high workability for extrusion forming process, and to use a Si powder, an Al—Si alloy powder or an Al—Si—Zn alloy powder as the brazing material contained in the flux layer 2.

A heat exchanger is manufactured using the conventional heat exchanger tube precursor 11 described above in a process such as: the heat exchanger tube precursors 11 are installed at right angles to the header pipes 5 that are disposed in parallel at a distance from each other, ends of the heat exchanger tube precursors 11 are inserted into openings (not shown) that are provided in the side face of the header pipe 5, the fins 6 having corrugated shape are assembled between the heat exchanger tube precursors 11, and the assembly is heated in a heating furnace so that the header pipes 5 and the tubes 1 are fastened to each other by brazing with the brazing material provided on the heat exchanger tube precursor 11 while the fins 6 of corrugated shape are fastened between the tubes 1, 1 by brazing.

Wall thickness of the tube 1 that constitutes the heat exchanger is made smaller than that of the header pipe 5 in order to achieve high efficiency of heat exchange. As a result, in the case in which the tube and the header pipe are corroded at comparable rates, it is likely that a penetrating hole will be formed by corrosion first in the tube thereby allowing the medium to leak therethrough. Thus, it has been a major concern in the heat exchanger to prevent corrosion of the tubes.

In order to improve the corrosion resistance of the heat exchanger tube 11, a sacrificial anode layer containing Zn as a major component is formed on the surface of the tubes in the conventional heat exchangers. As the process to form the sacrificial anode layer, such processes are known as thermal spraying of Zn and coating with a Zn-containing flux. Japanese Patent Application Unexamined Publication No. 7-227695 discloses an example that employs Zn-containing flux.

However, when forming the sacrificial anode layer by thermal spraying, it is difficult to precisely control the amount of metal applied by thermal spraying, thus leading to such a problem that the sacrificial anode layer cannot be formed uniformly on the tube surface, and the corrosion resistance of the tube cannot be improved.

When the Zn-containing flux described in Japanese Patent Application Unexamined Publication No. 7-227695 as mentioned above is used, it may be believed that corrosion resistance of the tube can be improved since the flux and Zn are supplied simultaneously onto the tube surface. In actuality, however, it is difficult to achieve a stable coating condition with ordinary coating methods such as immersion coating and roll coating, and therefore it has been difficult to uniformly apply the Zn-containing flux. As a result, Zn distribution in the sacrificial anode layer becomes uneven, thus leading to insufficient corrosion resistance of the tubes with preferential corrosion occurring in a portion that has higher concentration of Zn.

SUMMARY OF THE INVENTION

The present invention, which has been completed in view of the background described above, has an object of providing a heat exchanger tube precursor, which allows manufacturing a heat exchanger that has higher corrosion resistance.

In order to achieve the object described above, the present invention employs the following constitution.

The first aspect of the present invention is a heat exchanger tube precursor of the present invention includes: an Al alloy tube; and a flux layer including a Si powder, a Zn-containing flux, a Zn-free flux, and a binder, the flux layer being formed on an outer surface of the Al alloy tube.

In the first aspect of the present invention, an amount of the Si powder applied on the Al alloy tube may be in a range of 1 g/m² to 5 g/m², and an amount of the Zn-containing flux applied on the Al alloy tube is in a range of 3 g/m² to 20 g/m².

Also, in the first aspect of the present invention, the Si powder may have a particle diameter distribution such that 99% particle diameter (D₉₉) is 5 μm or more and 20 μm or less, and an amount of coarse particles having diameters of not smaller than 5 times (D₉₉) is less than 1 ppm by volume, wherein (D₉₉) denotes a critical diameter defined such that cumulative volume of particles not larger than (D₉₉) constitute 99% by volume of all the particles.

Also, in the first aspect of the present invention, 50% particle diameter (D₅₀) of the Si powder may be (D₉₉)×0.05 or more and (D₉₉)×0.7 or less, wherein (D₉₉) denotes a critical diameter defined such that cumulative volume of particles not larger than (D₉₉) constitute 99% by volume of all the particles, and (D₅₀) denotes a critical diameter defined such that cumulative volume of particles not larger than (D₅₀) constitute 50% by volume of all the particles.

Also, in the first aspect of the present invention, Zn-containing flux may contain at least one selected from ZnF₂, ZnCl₂ and KZnF₃.

Also, in the first aspect of the present invention, the Zn-free flux may contain at least one selected from LiF, KF, CaF₂, AlF₃, SiF₄, KAlF₄, and KAlF₃.

When such a heat exchanger tube precursor is used, since a mixture of the Si powder and the Zn-containing flux is applied, the Si powder melts and turns into a brazing liquid during a brazing process, and Zn contained in the flux is diffused uniformly in the brazing liquid and is distributed uniformly over the tube surface. Since the diffusion velocity of Zn in a liquid phase such as the brazing liquid is significantly higher than the diffusion velocity in the solid phase, Zn concentration in the tube surface becomes substantially uniform, thus making it possible to form a uniform sacrificial anode layer and improve the corrosion resistance of the heat exchanger tube.

It is preferable for maximum particle size of the Si powder to be 30 μm or less. Maximum particle size larger than 30 μm results in an increase in the erosion depth of the tube and is therefore not desirable. When maximum particle size of the Si powder is less than 0.1 μm, Si particles aggregate, and the erosion depth of the tube increases also in this case. Therefore, the maximum particle size is preferably not less than 0.1 μm.

Also, in the first aspect of the present invention, the Al alloy tube may be constituted of an alloy containing Si of 0.05% or more and 1.0% or less by weight, Mn of 0.05% or more and 1.2% or less by weight, and the balance being consisting of Al and inevitable impurities.

The second aspect of the present invention is a method of producing a heat exchanger tube precursor, the method including the steps of: classifying a pre-classification Si powder to obtain a post-classification Si powder in which 99% particle diameter (D₉₉) is 5 μm or more and 20 μm or less, an amount of coarse particles having diameters of not smaller than 5 times (D₉₉) is less than 1 ppm by volume, and 50% particle diameter (D₅₀) of the Si powder is (D₉₉)×0.05 or more and (D₉₉)×0.7 or less; preparing a coating material including the post-classification Si powder, a Zn-containing flux, a Zn-free flux, and a binder; and applying the coating material on an Al alloy tube, wherein an amount of the Si powder applied on the Al alloy tube is in a range of 1 g/m² to 5 g/m², an amount of the Zn-containing flux applied on the Al alloy tube is in a range of 3 g/m² to 20 g/m², (D₉₉) denotes a critical diameter defined such that cumulative volume of particles not larger than (D₉₉) constitute 99% by volume of all the particles, and (D₅₀) denotes a critical diameter defined such that cumulative volume of particles not larger than (D₅₀) constitute 50% by volume of all the particles.

In the second aspect of the present invention, the Zn-containing flux may contain at least one selected from ZnF₂, ZnCl₂, and KZnF₃.

In the second aspect of the present invention, the Zn-free flux may contain at least one selected from LiF, KF, CaF₂, AlF₃, SiF₄, KAlF₄, and KAlF₃.

In the second aspect of the present invention, the step of classifying may be performed by passing the pre-classification Si powder through a sieve. Alternatively, a cyclone may be used for classification in the step of classifying.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a heat exchanger tube precursor of the prior art.

FIG. 2 is a perspective view of a heat exchanger of the prior art.

FIG. 3 is photographic images of heat exchangers showing time degradation of the coating material.

DETAILED DESCRIPTION OF THE INVENTION

Next, preferred embodiments of the present invention will be described in detail.

The heat exchanger tube precursor of the present invention is made by forming the external surface of an Al alloy extruded tube with a flux layer containing a Si powder and a Zn-containing flux.

The Al alloy extruded tube which constitutes the heat exchanger tube precursor is made of an Al alloy containing Si and Mn, with the balance being Al and inevitable impurities, where a Si content is 0.5% by weight or more and 1.0% by weight or less, and a Mn content is 0.05% by weight or more and 1.2% by weight or less.

The reason for restricting the composition of the Al alloy extruded tube will be described below. Si has an effect in that a large amount of Si forms a solid solution in the Al alloy extruded tube, thus resulting in noble potential of the Al alloy extruded tube, and causes preferential corrosion to occur in the header pipes and the fins that are brazed with the tubes when assembling the heat exchanger, thereby suppressing deep pitting corrosion from occurring in the Al alloy extruded tube, while improving the brazing characteristic and forming good joint thereby to improve the strength after brazing. Si content of less than 0.5% cannot achieve the desired effect, and is therefore not desirable. Si content higher than 1.0%, on the other hand, lowers the melting point of the alloy resulting in excessive melting during brazing and poor extrusion forming characteristic, and is not desirable. Therefore, Si concentration in the Al alloy extruded tube is set in a range from 0.5 to 1.0%. More preferable range of Si concentration is from 0.6% to 0.8%.

Mn has the effect of turning the Al alloy extruded tube to noble potential and, because of less likelihood of diffusing in the brazing material, allows higher potential difference with the fin or the header pipe so as to make the corrosion preventing effect of the fin or the header pipe more effective, thereby improving the external corrosion resistance and the strength after brazing. Mn content of less than 0.05% cannot achieve sufficient effect of turning the Al alloy extruded tube to noble potential, and is therefore not desirable. Mn content higher than 1.2%, on the other hand, results in poor extrusion forming characteristic, and is not desirable.

Therefore, Mn concentration in the Al alloy extruded tube is set in a range from 0.05 to 1.2%.

The flux layer formed on the tube surface contains the Zn-containing flux and the Si powder, so that a molten brazing material layer is formed over the entire surface of the tube after brazing. Since the brazing material layer contains Zn uniformly distributed therein, the brazing material layer has similar effect as that of the sacrificial anode layer so that the brazing material layer is subject to preferential planar (general) corrosion. Therefore deep pitting corrosion can be suppressed and corrosion resistance can be improved.

The amount of a Si powder applied to the heat exchanger tube precursor is preferably not less than 1 g/m² and not more than 5 g/m². When the amount is less than 1 g/m², sufficient brazing strength cannot be achieved because of insufficient amount of the brazing material, and sufficient diffusion of Zn cannot be achieved. When the amount is more than 5 g/m², Si concentration in the tube surface increases and the rate of corrosion increases, and is therefore not desirable.

The flux layer contains at least the Zn-containing flux. In addition to the Zn-containing flux, a flux which does not contain Zn may also be contained.

The Zn-containing flux preferably contains at least one Zn compound selected from ZnF₂, ZnCl₂ and KZnF₃. The flux which does not contain Zn preferably contains at least one fluoride such as LiF, KF, CaF₂, AlF₃ or SiF₄ or a complex compound of the fluoride such as KAlF₄ or KAlF₃.

As the Zn-containing flux is contained in the flux layer of the heat exchanger tube precursor, a Zn-diffused layer (brazing material layer) is formed on the tube surface after brazing, so that the Zn-diffused layer functions as a sacrificial anode layer, thereby improving the anti-corrosion effect of the tube.

Also, because a mixture of the Si powder and the Zn-containing flux is applied, the Si powder melts and turns into a brazing liquid during a brazing process, Zn contained in the flux is diffused uniformly in the brazing liquid and is distributed uniformly over the tube surface. Since diffusion velocity of Zn in a liquid phase such as the brazing liquid is significantly faster than the diffusion velocity in a solid phase, Zn concentration in the tube surface becomes substantially uniform, thus making it possible to form a uniform Zn-diffused layer and improve the corrosion resistance of the heat exchanger tube.

The amount of the Zn-containing flux applied to the heat exchanger tube precursor is not less than 3 g/m² and not more than 20 g/m². An amount of less than 3 g/m² results in insufficient formation of a Zn-diffused layer that does not have sufficient anti-corrosion effect, and is therefore not desirable. An amount of more than 20 g/m² causes excessive Zn to be concentrated in a fillet that is the joint of the fin with other components which results in higher rate of corrosion in the joint, and is therefore not desirable.

The heat exchanger can be constituted by brazing the heat exchanger header pipes and the fins to the heat exchanger tube precursor described above.

That is, the heat exchanger is constituted from the heat exchanger tube precursor of the present invention, the heat exchanger header pipes and the fins that are joined with each other. Similarly to the heat exchanger described in conjunction with the prior art, the heat exchanger comprises a pair of right and left pipe bodies called “heat exchanger header pipes”, a plurality of heat exchanger tube precursors installed in parallel at intervals from each other between the heat exchanger header pipes, and fins installed between the heat exchanger tube precursors. The inner space of the heat exchanger tube precursor and the inner space of the heat exchanger header pipe are communicated with each other, so as to circulate a medium through the inner space of the heat exchanger header pipe and the inner space of the heat exchanger tube precursor, thereby to achieve efficient heat exchange via the fins.

The flux layer may be applied to the Al alloy tube with a roller coating apparatus. In this case, multiple Al alloy tubes are passed by the roller that is applied with a coating material (flux layer) in advance. In this way, the flux layer can be applied on an Al alloy tubes at once continuously. Alternatively, the flux layer can be applied on the Al alloy tube by thermal spraying. In addition to the methods described above, any conventional method for applying the coating material on a solid object can be used in the application process of the flux layer.

In order to obtain Si powder that has an intended specification, particularly in terms of their sizes, the Si powder is subjected to a classification process before preparing the coating material. For example, a commercially available Si powder (pre-classification Si powder) is subjected to a classification process in order to obtain the Si powder required to prepare the flux layer used in the first aspect of the present invention (post-classification Si powder).

The classification process includes the wet-type classification method, in which powder suspended in a liquid is subjected to classification, and dry-type classification method, in which a powder in a dried-form is subjected to the classification. In term of apparatus for the classification of Si powder, a single or multiple filters can be used for example. Alternatively, a cyclone apparatus can be used for classification. In addition to the methods described above, any conventional method can be used for classifying Si powder to prepare the post-classification Si powder.

Second Embodiment

In the following, another embodiment according to the present invention is explained.

A heat exchanger tube precursor of this embodiment is also constituted by forming a flux layer which includes Si powder and Zn-containing flux on an outer surface of an Al-alloy extruded tube (tube main body). In this embodiment, the flux layer further contains binder.

A main body of the heat exchanger tube precursor may be constituted of aluminum extruded tube or of aluminum alloy extruded tube.

The component of the Al alloy extruded tube may contains Si, Mn, and the balance being Al and inevitable impurities, where an amount of Si may be 0.05% by weight or more and 1.0% by weight or less, an amount of Mn may be 0.05% by weight or more and 1.2% by weight or less.

In the production process of a heat exchanger, it is preferable to constitute fins of a material (fin member) that has electric potential lower (less noble) than that of the tube.

In the following, reasons for limiting component elements of the heat exchanger tube precursor are explained.

Content of Si is important for forming moderate diffusion profile, and forming an uniform sacrificial anode layer. Where the amount of Si is less than 0.05% by weight, diffusion profile of Si has a large gradient, and it is difficult to form an uniform sacrificial anode layer. Where the amount of Si is more than 1.0% by weight, melting point of the alloy constituting the tube decreases, and extrudability of the alloy decreases. Therefore, in the present embodiment, the amount of Si contained in the alloy of the tube main body is controlled to be 0.05 to 1.0% by weight. More preferable Si content of the alloy is 0.1 to 0.6% by weight.

Mn forms an intermetallic compound with diffusing Si and is effective in forming an uniform sacrificial anode layer. In addition, Mn is also effective in improving corrosion resistance of the tube, improving mechanical strength of the tube, and improving extrudability of the alloy during forming the tube by extrusion.

Where the amount of Mn in the alloy is less than 0.05% by weight, diffusion profile of the Si has large gradient, and it is difficult to form an uniform sacrificial anode layer. Where the amount of Mn exceeds 1.2% by weight, extrudability of the alloy is decreased because of increasing extrusion pressure. Therefore, in the present embodiment, the amount of Mn contained in the alloy for constituting the tube is controlled to be 0.05 to 1.2% by weight. More preferable Mn content is 0.1 to 0.6% by weight.

Further, the Al alloy constituting the tube may further includes one or more selected from the group consisting of Fe: 0.1 to 0.6% by weight, Ti: 0.005 to 0.2% by weight, and Cu: 0.1% by weight or less.

Fe forms an intermetallic compound with diffusing Si and is effective in forming an uniform sacrificial anode layer. Where the amount of Fe is less than 0.1% by weight, diffusion profile of Si has a large gradient, and it is difficult to form a uniform sacrificial anode layer. Where the amount of Fe exceeds 0.6% by weight, intermetallic compound increases in the alloy constituting the tube, thereby tending to deteriorate the extrudability, resulting in short tool life of an extrusion die. More preferable Fe content is 0.15 to 0.5% by weight.

Ti forms fine intermetallic compound that does not inhibit corrosion resistance, and contributes to enhancement of strength of the tube 3. Where the amount of Ti is less than 0.005% by weight, no effective result can be obtained by the addition of Ti. Where the amount of Ti exceeds 0.2% by weight, extrudability of the tube alloy is deteriorated because of increasing extrusion pressure. More preferable Ti content is 0.005 to 0.1% by weight.

Cu is effective in raising the electric potential of the tube and maintaining the effect of the sacrificial anode layer for a long time. However, where the amount of Cu exceeds 0.1% by weight, corrosion rate increases, and the effect of the sacrificial anode layer is lost in the short time period. More preferable Cu content is less than 0.05% by weight.

The tube main body may be formed by extrusion of aluminum or aluminum alloy of the above-described composition. The extruded tube constituting the tube main body may be formed as a multi bore (port) extruded tube having a plurality of refrigerant passageways.

The extruded tube may have a surface constituted of two substantially flat main surfaces, two side surfaces, and two end surfaces in which opening of the refrigerant passageways are formed. The flux layer may be formed on the two main surfaces and the two side surfaces, or only on the two main surfaces.

Preferably, surface roughness of the extruded tube (tube main body) is less than 20 μm in R_(max).

The flux layer formed on the surface of the tube includes Zn-containing flux, Si powder, and binder.

Preferably, the Zn containing flux contains one or more Zn compound selected from the group consisting of ZnF₂, ZnCl₂, and KZnF₃. The Zn containing flux may be consisting of the above-described Zn compound. Alternatively, the Zn-containing flux may be a mixture of the above-described Zn compound and another flux. For example, one or two or more selected from the group consisting of LiF, KF, CaF₂, AlF₃, SiF₄, K_(1-3AlF4-6), Cs_(1-3AlF4-6), Cs₀.02K_(1-2AlF4-5), K_(2SiF6) may be included in the Zn containing flux. Preferably, the Zn containing flux may have a particle diameter of 1 to 6 μm in mean particle diameter (D₅₀).

Where the Zn containing flux is formed as a mixture of Zn compound and Zn-free flux, it is preferable to control the amount of Zn compound applied on the tube surface to be 3 g/m² or more.

Acrylic based resin may be used as the binder. Where the acrylic based resin is used as the binder, the resin has an effect of adhering the components of the flux layer such as Si powder and fluoride based flux to the surface of the tube, and preventing delamination of the flux layer from the tube during the pre-brazing process such as assembling process of the heat exchanger. In addition, since the acrylic based resin is easily decomposed and evaporated during heating in the process of brazing, brazeability and corrosion resistance of the tube are not deteriorated. Therefore, the acrylic based resin is preferred as the binder.

In the present embodiment, 99% particle size (D₉₉) of the Si powder contained in the flux layer is preferably 5 μm or more and 20 μm or less, where 99% particle diameter denotes a critical diameter defined such that cumulative volume of particles having the diameters of not greater than the diameter constitute 99% of the volume of the whole powder. Further, amount of coarse particles having a particle diameter (hereafter referred to as D_(coarse)) of not smaller than (D₉₉)×5 is preferably less than 1 ppm by volume.

Where the Si powder has a particle size of 20 μm or less in 99% particle diameter (D₉₉), it is possible to form an uniform sacrificial anode layer. On the other hand, where 99% particle diameter exceeds 20 μm, localized deep erosion is generated, and it is difficult to form a uniform sacrificial anode layer. Therefore, particle diameter of Si powder is preferably 20 μm or less in 99% particle diameter (D₉₉). Where the Si powder has a particle diameter of less than 5 μm in 99% particle diameter (D₉₉), Si powder as a whole has fine particle diameter. Since the fine Si particle tends to accumulate with each other, granulation or aggregation of powder particles easily occurs in the powdered brazing composition formed by mixing the Si powder, flux, and binder.

More preferably, (D₉₉) of the Si powder is 5 μm or more and 15 μm or less.

Based on the above-described reason, the Si powder preferably has a particle diameter distribution such that 99% particle diameter (D₉₉) is 5 μm or more and 20 g m or less, and an amount of coarse Si particles of not smaller than 5 times the 99% particle diameter (D₉₉) is less than 1 ppm.

More preferably amount of the coarse Si particles of not smaller than 5 times the 99% particle diameter (D₉₉) is less than 0.5 ppm, more preferably less than 0.1 ppm.

Preferably, mean diameter (D₅₀) of the Si powder is in the range of not smaller than 0.05 times the 99% particle diameter (D₉₉) and not larger than 0.7 times the 99% particle diameter (D₉₉), where the mean diameter (D₅₀) denotes a critical particle diameter defined by the fact that cumulative volume of Si powder of not larger than that diameter constitute 50% by volume of the whole Si powder. Where the Si powder applied on the surface of the tube has a mean diameter (D₅₀) of not smaller than 0.05 times the 99% particle diameter (D₉₉) and not larger than 0.7 times the 99% particle diameter (D₉₉), uniform sacrificial anode layer is formed after the heating in the brazing process. On the other hand, where the Si powder applied on the surface of the tube has a mean diameter (D₅₀) larger than 0.7 times the 99%, relatively coarse particles are dispersed on the surface of the tube. As a result, the sacrificial anode layer formed after the brazing tends to have spot like distribution of deep (thick) portions. As a result, area in which Zn is not diffused is distributed between the spot like sacrificial anode layers. In such a case, by a large potential difference between the area of sacrificial anode layer and the area in which Zn is not diffused, there is a possibility of occurrence of localized deep corrosion.

Where the Si powder has a small mean diameter less than 0.05 times (D₉₉), granulation tends to occur by accumulation of the fine particles.

Based on the above-explained reason, mean diameter (D₅₀) of Si powder is preferably not smaller than 0.05 times the 99% particle diameter (D₉₉) and not larger than 0.7 times the 99% particle diameter (D₉₉).

Amount of Si powder applied on the surface of the tube (heat exchanger tube precursor) is preferably 1 g/m² or more and 5 g/m² or less. Where the amount of Si powder is less than 1 g/m², brazing filler is not formed sufficiently, and it is difficult to form an uniform sacrificial anode layer. On the other hand, where the amount of Si powder exceeds 5 g/m², noble cathode layer is formed on the surface of the sacrificial anode layer. As a result, effect of the sacrificial anode layer is lost in a short time period. Therefore, amount of the Si powder in the coating (flux layer) is preferably 1 to 5 g/m².

The amount of Zn-containing flux applied on the surface of the heat exchanger tube precursor is preferably in the range of 3 g/m² or more and 20 g/m² or less. Where the amount of the Zn-containing fluoride based flux in the coating (flux layer) is less than 3 g/m², it is difficult for the sacrificial anode layer to exert the sacrificial anode effect because of small potential difference. In addition, decomposition and removal of surface oxide layer of the member to be brazed (tube) tends to be insufficient. On the other hand, where the amount of the Zn-containing fluoride based flux in the coating exceeds 20 g/m², corrosion rate of the sacrificial anode layer is increased because of large potential difference. As a result, corrosion protection effect by the presence of the sacrificial anode layer is lost in a short time.

More preferable amount of the Zn-containing flux is 4 g/m² or more and 15 g/m² or less.

In addition to the Si powder and the Zn-containing fluoride based flux, the coating composition includes binder. For example, acrylic base resin may be used as the binder. The binder has an effect of adhering the Si powder and the Zn containing flux (necessary materials in the formation of the sacrificial anode layer) to the surface of the tube. Where the amount of binder in the coating is less than 0.2 g/m², there is a possibility of failing formation of an uniform sacrificial anode layer by dropping out of the Si powder and/or Zn-containing flux from the tube during the brazing process. On the other hand, where the amount of binder exceeds 8.3 g/m² by weight, brazeability is deteriorated by the presence of residue of the binder, and it is difficult to form an uniform sacrificial anode layer. Therefore, it is preferable to control the amount of the binder in the coating to be in the range of 0.2 to 8.3 g/m². In usual, the binder is evaporated by heating during the brazing process.

More preferable amount of the binder coated on the surface of the tube is 0.3 g/m² or more and 7 g/m² or less. Preferably, the amount of the binder is controlled to be in the range of 5% to 25% or the total amount of the Si powder and the Zn containing flux and binder in the coating.

A heat exchanger may be constituted by brazing headers and fins for heat exchanger to the above-described heat exchanger tube precursor.

A heat exchanger is constituted by joining the above-described tubes, header pipes, and fins. A pair of pipes so called header pipes is arranged with a clearance in between in vertical or lateral (horizontal) direction. A plurality of tubes is arranged between the header pipes. Openings corresponding to the numbers of the tubes are opened in one side of each header pipe. For example, the tubes and header pipes are assembled by inserting the end portions of the tubes into the openings of the header pipes. Plate members so called fins are arranged between each pair of the adjacent tubes. The fin may be a corrugated fins made by working a plate into a corrugated (wavy) shape.

After assembling the tubes, fins, and header pipes, the assembled body is heated at a predetermined temperature, for example, at 580 to 615° C. During the heating, melting of flux is followed by melting of the Si powder, and brazing liquid is formed. The brazing liquid includes Zn of the flux, Si of the silicon powder, and alloy components of the surface portion of the tube main body eutectically molten with the Si powder. The brazing liquid is solidified by cooling and forms a brazing filler layer.

Zn is uniformly distributed by diffusion in the brazing liquid, and also diffuses into the Al alloy of the tube main body. As a result, an uniform Zn diffused layer is formed on the surface of the tube.

In the process of heat exchange, medium is circulated in the inner space of each header pipes and tubes, and heat exchange can be performed effectively via the fins having large contact surfaces with the outer environment.

The flux layer may be applied to the Al alloy tube with a roller coating apparatus. In this case, an Al alloy tube is passed by the roller that is applied with a coating material (flux layer) in advance. In this way, the flux layer can be applied on numbers of Al alloy tubes at once continuously. Alternatively, the flux layer can be applied on the Al alloy tube by thermal spraying. In addition to the methods described above, any conventional method for applying the coating material on a solid object can be used in the application process of the flux layer.

In order to obtain Si powder that has an intended specification, particularly in terms of their sizes, the Si powder is subjected to a classification process before preparing the coating material. For example, a commercially available Si powder (pre-classification Si powder) is subjected to a classification process in order to obtain the Si powder required to prepare the flux layer used in the first aspect of the present invention (post-classification Si powder).

The classification process includes the wet-type classification method, in which powder suspended in a liquid is subjected to classification, and dry-type classification method, in which a powder in a dried-form is subjected to the classification. In term of apparatus for the classification of Si powder, a single or multiple filters can be used for example. Alternatively, a cyclone apparatus can be used for classification. In addition to the methods described above, any conventional method can be used for classifying Si powder to prepare the post-classification Si powder.

Third Embodiment

In the following, another embodiment according to the present invention is explained.

The third embodiment differs from the first and the second embodiments in having both the Zn-containing flux and the Zn-free flux at the same time in the flux layer applied on the Al alloy tube. Any other configurations described in the first and the second embodiments can be adopted in the third embodiment of the present invention.

As explained above, the flux layer formed on the surface of the tube includes a Zn-free flux, in addition to the Si powder, the Zn-containing flux, and binder in the present embodiment. The Zn-free flux is a chemical composition included in the flux layer to destroy the oxide film formed on the surface being soldered. The Zn-free flux does not contain Zn. During process, the Zn-free flux destroys the oxidized film formed on the soldering surface together with the Zn-containing flux, improving solderability at the joint.

Therefore, two different kinds of flux, the Zn-free and Zn-containing fluxes, are used at the same time. In terms of the Zn-containing flux, those named in the explanations in the first and second embodiments can be used.

The Zn-free flux contains at least fluoride such as LiF, KF, CaF₂, AlF₃ or SiF₄, or a complex compound of the fluoride such as KAlF₄ or KAlF₃. Alternatively, the Zn-free flux contains one or more selected from the group consisting LiF, KF, CaF₂, AlF₃, SiF₄, K₁₋₃AlF₄₋₆, Cs₁₋₃AlF₄₋₆, Cs_(0.02)K₁₋₂AlF₄-5, and K₂SiF₆.

By using the two different kinds of flux, the Zn-free and Zn-containing fluxes, Zn content in the coating material (flux layer) can be controlled. By controlling the Zn content in the coating material, the preferential corrosion in the fillet part of the joint can be prevented, for example. The preferential corrosion occurs when the fillet part includes a much higher Zn content compared to other coated part.

In addition to the technical effect explained above, time degradation of the coating material can be suppressed by having the Zn-free and the Zn-containing fluxes in the flux layer at the same time.

When the Al alloy tube applied with the coating material (flux layer) is kept under a higher temperature than normal room temperature, such as 40° C. or higher, and a higher humidity, such as 98% or higher, for a certain period of time, such as 7 days or longer, the performance of the flux layer deteriorates, if the flux layer only includes the Zn-containing flux.

Specifically, when the Al alloy tube applied a flux layer including only the Zn-containing flux as a flux is kept under the condition described above, a larger amount of the Si powder is not melted during brazing process causing poor soldering and a higher susceptibility to corrosion.

However, such a time degradation of the flux layer under the circumstance can be suppressed by including the both Zn-free and Zn-containing fluxes in the flux layer.

The amount of Zn-containing flux applied on the surface of the heat exchanger tube precursor is preferably in the range of 3 g/m² or more and 20 g/m² or less. Where the amount of the Zn-containing fluoride based flux in the coating (flux layer) is less than 3 g/m², it is difficult for the sacrificial anode layer to exert the sacrificial anode effect because of small potential difference. In addition, decomposition and removal of surface oxide layer of the member to be brazed (tube) tends to be insufficient. On the other hand, where the amount of the Zn-containing fluoride based flux in the coating exceeds 20 g/m², corrosion rate of the sacrificial anode layer is increased because of large potential difference. As a result, corrosion protection effect by the presence of the sacrificial anode layer is lost in a short time.

More preferable amount of the Zn-containing flux is 4 g/m² or more and 15 g/m² or less.

The amount of Zn-free flux applied on the surface of the heat exchanger tube precursor is preferably in the range of 1.2 g/m² or more and 26 g/m² or less. Where the amount of the Zn-free flux in the coating (flux layer) is less than 1.2 g/m², degradation of the heat exchanger due to humidity is accelerated. In addition, the Zn content is increased at the fillet part making the fin part prone to be separated after the brazing process. On the other hand, where the amount of the Zn-free flux in the coating exceeds 26 g/m², it is wasteful since there is no improvement on the corrosion resistance.

More preferable amount of the Zn-free flux is 2 g/m² or more and 20 g/m² or less.

It is preferable that the amount ratio between Zn-containing flux and Zn-free flux is in the range of 10:4 to 10:13 as the mass per area unit (g/m²).

The flux layer may be applied to the Al alloy tube with a roller coating apparatus. In this case, multiple Al alloy tubes are passed by the roller that is applied with a coating material (flux layer) in advance. In this way, the flux layer can be applied on numbers of Al alloy tubes at once continuously. Alternatively, the flux layer can be applied on the Al alloy tube by thermal spraying. In addition to the methods described above, any conventional method for applying the coating material on a solid object can be used in the application process of the flux layer.

In order to obtain Si powder that has an intended specification, particularly in terms of their sizes, the Si powder is subjected to a classification process before preparing the coating material. For example, a commercially available Si powder (pre-classification Si powder) is subjected to a classification process in order to obtain the Si powder required to prepare the flux layer used in the first aspect of the present invention (post-classification Si powder).

The classification process includes the wet-type classification method, in which powder suspended in a liquid is subjected to classification, and dry-type classification method, in which a powder in a dried-form is subjected to the classification. In term of apparatus for the classification of Si powder, a single or multiple filters can be used for example. Alternatively, a cyclone apparatus can be used for classification. In addition to the methods described above, any conventional method can be used for classifying Si powder to prepare the post-classification Si powder.

EXAMPLES Examples A

Al alloy extruded tubes having 10 cooling medium passing holes and cross section measuring 20 mm in width, 2 mm in height and wall thickness of 0.20 mm were produced, by extrusion forming of billets made of an Al alloy containing 0.7% by weight of Si and 0.5% by weight of Mn.

Then a flux mixture was prepared by mixing the Zn-containing flux to Si powder. The flux mixture was applied by spraying onto the outer surface of the Al alloy extruded tube that was produced in advance, thereby forming a flux layer. The amounts of the Si powder and the flux mixture applied to the Al alloy extruded tube are shown in Table 1. Thus the heat exchanger tube precursors of Examples 1 to 6 and Comparative Examples 1 to 4 were produced.

Then fins made of cladding material (JIS3003 or JIS3003/JIS4045) were assembled on the heat exchanger tube precursors of Examples 1 to 6 and Comparative Examples 1 to 4, and the assemblies were kept at 600° C. in a nitrogen atmosphere for three minutes so as to carry out brazing. The tubes with the fins brazed thereon were subjected to corrosion tests (SWAAT, 20 days) to measure the maximum corrosion depth of the tubes. The test results are shown in Table 1.

TABLE 1 Si powder Maximum Flux Maximum Amount of particle size Amount of corrosion depth coating (g/m²) (μm) Composition coating (g/m²) Fin (μm) Remark Example 1 1 10 KZnF₃ 5 JIS3003 75 — Example 2 3 10 KZnF₃ 10 JIS3003 70 — Example 3 5 10 KZnF₃ 15 JIS3003 80 — Example 4 5 10 KZnF₃ 20 JIS3003 75 — Example 5 3 10 ZnCl₂ + 10 + 10 JIS3003 95 — KAlF₄ Example 6 3 35 KZnF₃ 10 JIS3003 80 somewhat deep erosion Comparative 3 10 KAlF₄ 10 JIS3003 350 — Example 1 Comparative 3 10 KZnF₃ +  2 + 10 JIS3003 300 — Example 2 KAlF₄ Comparative — — ZnF₂ 10 JIS3003/ 175 — Example 3 JIS4045 Comparative — — KZnF₃ 20 JIS3003/ 200 — Example 4 JIS4045

As shown in Table 1, maximum corrosion depth was less than 100 it m in any of the finned tubes of Examples 1 to 6, indicating that corrosion of the tubes was suppressed. Example 6 showed a little deeper erosion because of larger maximum particle size of the Si powder.

Extent of corrosion was larger in the comparative examples, presumably because Zn was not added to the flux in Comparative Example 1, smaller amount (2 g/m²) of the Zn-containing flux (KZnF₃) was added in Comparative Example 2, and Zn was distributed unevenly since Si powder was not added in the comparative examples 3 and 4.

Examples B

Multi-bore (Multi-port) extruded tubes each having a dimension of 1.5 mm in height, 14 mm in width, 500 mm in length, and 0.4 mm in wall thickness were produced by extrusion of aluminum alloy having a composition of Al-0.3% Si—0.3% Fe-0.3% Mn-0.05% Ti. 39 tubes were prepared. Coating in an amount of 9.5 g/m² of powdered brazing composition containing a Si powder, a KZnF₃ flux, an acrylic resin binder was applied on the surface of each tube, where fraction of each component was controlled such that Si powder:KZnF₃ flux:acrylic resin=2.6:5.7:1.2 (g/m²). Each tube was subjected to heating for brazing at 600° C. for 2.5 minutes in a furnace of nitrogen atmosphere.

Particle diameter distribution of Si powder was controlled as shown in Table 2 by measuring the diameter distribution using the below explained laser diffraction particle diameter analyzer, and grading the particle diameter by sieving.

Method of Controlling the Particle Diameter Distribution of Si Powder.

1. Firstly commercially available Si powder of a predetermined grade is prepared. In this stage, it is impossible to analyze the distribution of coarse grains by the laser diffraction particle diameter analyzer. Commercially available powders are provided with data of particle diameter distribution. However, those powders include substantial amounts of coarse particles not described in the data. 2. The Si powder is sieved using a sieve having a mesh aperture size of (D₉₉)×5. 3. The powder is subjected to grading of particle diameter by sieving. 4. After the sieving, particles remaining on the sieve are mainly constituted of coarse particles. Therefore, it is possible to analyze particle diameter distribution using the laser diffraction type particle diameter analyzer. 5. By adding a necessary amount of the above-described coarse Si particles to the Si powder having a particle diameter of a certain diameter or less, Si powder containing a desired amount of coarse Si particles is prepared. 6. By the above-described process, it is possible to control the amount of coarse Si powder to be a calculated value.

Si powders of the thus controlled particle diameter distribution were used in the testing.

The 39 tubes subjected to heating process equivalent to brazing at 600° C. for 2.5 minutes were subjected to SWAAT test for 11 days, and maximum depth of corrosion generated in the coated portion was measured by focal depth method.

With respect to the thus obtained Examples B1 to B36 and Comparative Examples B1 to B3, amount of Si powder in the coating (flux layer), 99% particle diameter of the Si powder, amount of coarse Si particles having a diameter of not smaller than 5 times (D₉₉), ratio of (D₃₀)/(D₉₉) of the Si powder, amount of KZnF₃ flux in the coating, maximum depth of corrosion, and numbers of corroded portions having a depth of 120 μm or more measured as a result of corrosion test of each tube are shown in the below Tables 2 and 3.

TABLE 2 Number of Si powder corrosion Amount having a of Flux Maximum depth of Amount D₉₉ D_(course) Amount Amount corrosion 120 μm (g/m²) (μm) (ppm) D₅₀/D₉₉ Composition (g/m²) Fin depth (μm) or more Example B1 2 5 0.02 0.3 KZnF₃ 15 JIS3003 85 0 Example B2 3 10 0.05 0.35 KZnF₃ 5 JIS3003 90 0 Example B3 3 20 0.02 0.4 KZnF₃ 3 JIS3003 95 0 Example B4 4 5 0.02 0.3 KZnF₃ 6 JIS3003 91 0 Example B5 2.5 10 0.05 0.35 KZnF₃ 15 JIS3003 93 0 Example B6 4 20 0.02 0.4 KZnF₃ 15 JIS3003 98 0 Example B7 3 10 0.01 0.35 KZnF₃ 20 JIS3003 74 0 Example B8 2.5 10 0.1 0.35 KZnF₃ 3 JIS3003 130 1 Example B9 3 10 0.5 0.35 KZnF₃ 6 JIS3003 125 4 Example B10 3 10 0.9 0.35 KZnF₃ 4 JIS3003 125 8 Example B11 1 20 0.05 0.04 KZnF₃ 5 JIS3003 125 20 Example B12 2.5 20 0.02 0.05 KZnF₃ 10 JIS3003 95 0 Example B13 3.5 20 0.02 0.5 KZnF₃ 5 JIS3003 84 0 Example B14 3.5 20 0.01 0.7 KZnF₃ 15 JIS3003 92 0 Example B15 3 20 0.05 0.8 KZnF₃ 8 JIS3003 131 0 Example B16 1.5 5 0.02 0.3 KZnF₃ 3 JIS3003 115 0 Example B17 1.5 10 0.05 0.35 KZnF₃ 5 JIS3003 100 0 Example B18 1.5 15 0.03 0.4 KZnF₃ 15 JIS3003 90 0 Example B19 1.5 20 0.02 0.4 KZnF₃ 10 JIS3003 92 0

Remark:

D_(course) denotes particles having a diameter of 5 times (D₉₉) or more.

TABLE 3 Number of Si powder Maximum corrosion Amount Amount Flux corrosion having a depth Amount D₉₉ of D_(course) of Amount depth of 120 μm or (g/m²) (μm) (ppm) D₅₀/D₉₉ Composition (g/m²) Fin (μm) more Example B20 1.5 20 0.02 0.4 KZnF₃ 10 JIS3003 92 0 Example B21 1.5 10 0.05 0.35 KZnF₃ 20 JIS3003 80 0 Example B22 2.5 15 0.03 0.4 KZnF₃ 20 JIS3003 78 0 Example B23 2.5 5 0.02 0.3 KZnF₃ 5 JIS3003 110 0 Example B24 3 5 0.02 0.3 KZnF₃ 15 JIS3003 97 0 Example B25 4.5 5 0.02 0.3 KZnF₃ 3 JIS3003 110 0 Example B26 4.5 10 0.05 0.35 KZnF₃ 5 JIS3003 88 0 Example B27 4.5 15 0.03 0.4 KZnF₃ 10 JIS3003 90 0 Example B28 4.5 20 0.02 0.4 KZnF₃ 15 JIS3003 80 0 Example B29 4.5 15 0.03 0.4 KZnF₃ 20 JIS3003 85 0 Example B30 2 15 0.03 0.4 KZnF₃ 20 JIS3003 80 0 Example B31 2 20 0.02 0.4 KZnF₃ 10 JIS3003 90 0 Example B32 3 15 0.03 0.4 KZnF₃ 14 JIS3003 87 0 Example B33 3.5 5 0.02 0.3 KZnF₃ 20 JIS3003 81 0 Example B34 3.5 10 0.05 0.35 KZnF₃ 10 JIS3003 88 0 Example B35 3.5 15 0.03 0.4 KZnF₃ 3 JIS3003 115 0 Example B36 4 10 0.05 0.35 KZnF₃ 3 JIS3003 110 0 Comparative B1 3 2 0.05 0.3 KZnF₃ 2 JIS3003 140 not measured Comparative B2 5 30 0.01 0.4 KZnF₃ 1.7 JIS3003 185 not measured Comparative B3 2 10 1 0.35 KZnF₃ 4 JIS3003 160 not measured

As shown in Table 2, 3, in each of the tubes of Examples B1 to B36 brazed with the fins, numbers of generation of corrosion pits having a depth of 120 μm or more were 20 or less. That is, practical corrosion protection effect was ensured.

In the Comparative Examples B1 to B3, maximum depth of corrosion was 140 μm or more. Since the unsatisfactory corrosion protection was obvious, numbers corrosion pits having a depth of 120 μm or more were not measured in the Comparative Examples B1 to B3.

In the Comparative Example B1, granulation occurred because of small (D₉₉). In addition, amount of Zn containing flux was small. As a result, maximum corrosion depth had a large value of 140 μm.

In the Comparative Example B2, aggregation occurred because of large (D₉₉). In addition, amount of Zn containing flux was small. As a result, maximum corrosion depth had a large value of 185 μm.

As described in detail above, in the heat exchanger tube precursor of the present invention, since the mixture of the Si powder and the Zn-containing flux is applied, the Si powder melts and turns into a brazing liquid during a brazing process, while Zn contained in the flux is diffused uniformly in the brazing liquid and is distributed uniformly over the tube surface. Since diffusion velocity of Zn in a liquid phase such as the brazing liquid is significantly higher than diffusion velocity in a solid phase, Zn concentration in the tube surface becomes substantially uniform, thus making it possible to form a uniform sacrificial anode layer and improve the corrosion resistance of the heat exchanger tube.

Since the amount of the Zn-containing flux is in a range not less than 5 g/m² and not more than 20 g/m², Zn can be distributed uniformly over the tube surface.

In addition, by controlling the particle diameter distribution of the Si powder, it is possible to form uniform distribution of Zn on the tube surface even when the amount of Zn containing flux is 3 g/m² or more and 20 g/m² or less.

Examples C

Multi-bore (Multi-port) extruded tubes each having a dimension of 1.5 mm in height, 14 mm in width, 500 mm in length, and 0.4 mm in wall thickness were produced by extrusion of aluminum alloy having a composition of Al-0.3% Si—0.3% Fe-0.3% Mn-0.05% Ti. 39 tubes were prepared. Coating in an amount of 9.5 g/m² of powdered brazing composition containing a Si powder, a KZnF₃ flux, a Zn-free flux, such as KAlF₄, KAlF₆, K₂AlF₅.H₂O, AlF₃, and the like, an acrylic resin binder was applied on the surface of each tube, where fraction of each component was controlled such that Si powder:KZnF₃ flux:acrylic resin=2.6:5.7:1.2 (g/m²).

After application of the coating material on the Al alloy tube, the heat exchanger tube precursors were kept in two different conditions. One condition is the normal condition, and they were kept in normal room temperature (about 25° C.) and normal humidity (30 to 60%) for 7 days. Other is the stringent condition, and they were kept in a condition where the temperature is 40° C. and humidity is 98% for 7 days. After the storage period, each tube was assembled with head and fin portions and subjected to heating for brazing at 600° C. for 2.5 minutes in a furnace of nitrogen atmosphere.

After brazing treatment, the header pipe and fin portions were disassembled from the heat exchange tube in order to observe the top surface of the tubes.

FIG. 3 is photographic images of heat exchangers showing time degradation of the coating material. The coating material was applied on the Al alloy tube. Then, the heat exchanger tube precursors were left in conditions indicated on top. Then, heat exchangers were assembled and subjected brazing treatment. Header pipes and fin were disassembled to observe the top surface of the brazed tubes. The bright area indicates the area the Si powder is melted properly and the dark area indicates the area that the coating material was deteriorated. In the area, the Si powder was not melted. The fine vertical lines correspond to the part fin portions being attached.

In the heat exchanger tubes stored in the normal condition, the Si powder was properly melted, Zn was diffused properly, and corrosion-resistance was obtained in the entire surface of the tubes regardless of the Zn-free flux contents. However, when the heat exchanger tubes were stored in the stringent condition, time degradation of the coating materials was observed.

Dark areas not observed in the normal condition appeared on some of the heat exchanger tubes stored in the stringent condition. The largest dark area was observed in the heat exchanger tube applied with a coating material not including the Zn-free flux content (compare two images on the top row).

The dark area decreased when the Zn-free flux was added. When the Zn-free flux content was increased to 5 g/m², the surface covered by the localized dark area is decreased.

The result indicates that time degradation of the coating material can be suppressed by including both the Zn-free flux and the Zn-containing flux in the coating material even if the tubes were stored under a stringent condition (a higher temperature and a higher humidity).

While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, omissions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as being limited by the foregoing description, and is only limited by the scope of the appended claims. 

1. A heat exchanger tube precursor comprising: an Al alloy tube; and a flux layer including a Si powder, a Zn-containing flux, a Zn-free flux, and a binder, the flux layer being formed on an outer surface of the Al alloy tube. 2-10. (canceled) 